Wood reinforced shipping carton



Jan. 26, 1965 Filed April 1, 1963 T. MUNROE WOOD REINFORCED SHIPPINGCARTON 2 Sheets-Sheet 1 41mm}? 5 I", I llullllm o 0 IN VENTOR. MUA//?0T. MUNROE WOOD REINFORCED SHIPPING CARTON Jan. 26, 1965 2 Sheets-Sheet 2Filed April 1, 1963 A my,

a, E m W v y United States Patent Ofiice ddiilfldd Fatented Jan. 26,1965 3,167,234 WOOD REENEGRCED SHIPPING CARTGN Thomas Munroe, Dayton,Ghio, assignor to Moraine Box Company, Dayton, Ghio, a corporation ofOhio Filed Apr. 1, M63, Ser. No. 269,822 6 Claims. (Cl. 229--23) Thisinvention relates to cartons and particularly to corrugated papercartons having wood reinforced panels therein, and more particularlystill, the invention relates to a carton of the nature referred to inwhich the carton can be made up and closed without the use of nails orstaples or adhesives or any other separate fastening means.

Boxes and cartons which can be closed without the use of any fasteningmeans are, of course, known with respect to smaller cardboard cartonsthat are employed, particularly in retail establishments, for carrying.light articles. Cartons or boxes of this nature usually haveinterlocking tabs or slots for interconnecting closure flaps so that nofastening means are required.

It is also known to provide small corrugated paper cartons in whicharticles of commerce, such as small electric motors and the like areplaced in which no nails or other fastening means are required, butwherein the closure flaps for the carton are either glued closed or aretaped closed. I

To my knowledge, however, there has never been a carton of thecorrugated paper type having wood reinforced panels in which the cartoncan be set up and closed without the use of any fastening meanswhatsoever. It is in connection with a carton of this type that thepresent invention is primarily concerned.

The carton of the present invention is somewhat related to the cartonsdisclosed in my issued Patents 3,029,995 and 2,972,440 wherein acorrugated paper blank is provided that makes up three or four sides ofa carton and which completed carton includes at least two reinforcedpanels to which the other panels of the carton are attached by nails orstaples. The present invention represents a departure from the inventiondisclosed in the patents referred to above in that, while a corrugatedpaper blank is employed for making up the carton and in combination withwood reinforced panels, there is no stapling or nailing required toconnect the wood reinforced panels to the other panels of the cartoneither for assembling the carton initially or for setting the carton upand closing it.

With the foregoing in mind, a primary object or" the present inventionis the provision of a carton which can be made up and closed ready forshipment without using any nails or staples or other fasteners orwithout requiring any machines for fastening the several panels of thecarton together.

Another object of this invention is the provision of a corrugated papercarton arrangement that can be manufactured and shipped fiat and whichcan readily be set up at the point of use without any tools and thenclosed up ready for shipment without the use of any tools or fasteners.

The foregoing objects as well as other objects and advantages willbecome more apparent upon reference to the following specification takenin connection with the accompanying drawings in which:

FIGURE 1 is a perspective view showing a carton according to the presentinvention set up and closed ready for shipment;

FIGURE 2 is a plan view showing the basic corrugated paper blank fromwhich the carton is made and the wood reinforced end panels that closethe ends of the carton;

FIGURE 3 is a vertical sectional view indicated by line 3-3 on FIGURE 1showing the one end panel and the connection thereof to the top andbottom walls of the carton;

FIGURE 4 is a plan sectional view indicated by line 4-4 on FIGURE 1showing the same wood reinforced end panel of the carton and the mannerin which the front and back panels of the carton blank are connectedthereto;

FIGURE 5 is a fragmentary perspective view showing how the wood railsreinforcing the end panels are joined and are connected to thecorrugated paper member which, together with the rails, makes up the endpanel;

FiGURE 6 is a perspective view of the carton of PEG- URE 1 showing it inthe process of being set up;

FZGURE 7 is a fragmentary view drawn at enlarged scale and showing thetop panel of the carton being joined to the top rail of one of the endpanels;

FIGURE 8 is a perspective view of a modified form of the carton in whichthe top divided panel is reinforced with wood rails;

FiGURE 9 is a view like FIGURE 8 but shows how the reinforcing of theparts of the top panel could be applied to the underneath side thereof;

FIGURE 10 is a perspective view showing one end of a carton having pulltabs by means of which the carton can be easily opened;

FEGURE 11 is a sectional view indicated by line 11-11 on FIGURE 10;

FIGURE 12 is a view like FIGURE 10 but showing a modified arrangement;

lGURE 13 is a fragmentary perspective view showing another modifiedarrangement; and,

FIGURE 14 is a fragmentary view showing a different manner of formingthe wood reinforced end member.

Referring to the drawings somewhat more in detail, and with particularreference to FIGURES 1 thru 7, the carton according to the presentinvention comprises wood reinforced end panels llll and 12. Each ofthese panels consists of a top rail 14, a bottom rail 15, and end rails16 and 18 all of wood, forming a rectangle and having attached thereto acorrugated paper member 20. According to the preferred form of thepresent invention, member 2d is connected to wood rail frame by six nailor fasteners 22 which are located in the corners of the end panels andintermediate the ends of the top and bottom rails.

As will be seen in FIGURE 5, the rails in the corners of the end panelsare employed not only for holding the corrugated paper member 29 to therails but also serve to interconnect the top and bottom rails with theend rails. These rails are advantageously formed so that one has agroove or slot 24 therein and the other has a tongue or tenon 26 that isreceivable in the slot. Preferably the tongue is tapered at the ends asat 28 so that it can be formed for a close fit in the slot but can beeasily inserted therein. This arrangement, particularly where theshoulder 39 at the base of the tongue abut the adjacent top or bottomrail, providesfor an extremely rigid end panel structure.

The end panels, which are identical for both ends of the carton, arejoined with the main carton blank to make up the completed carton. Themain blank is illustrated in developed form in FIGURE 2 and is adaptedfor forming the bottom, side and top walls of the carton, as will beseen in FIGURES 1 and 6. This blank is generally indicated at 32 andcomprises a rectangular sheet of corrugated paper scored along line 34so as to be readily foldable, said score lines defining the bottom panelas, the side panels 33 .and the two half panels 40 which, together, makeup the top panel of the carton.

Extending from each of the aforementioned panels are flaps which arejoined with the panels 36, 58 and 40 their ends formed inwardly at anangle as at 52 adja cent flap 36, and then having a straight portion 54and a final tapered corner 56. The formation of the ends of the flapsare required so that when the carton blank is folded up, .the end flapscan be formed around the wood' rails without interfering with eachother.

Extending from opposite ends of the side panels 38 of the carton blankare flaps 58 formed similarly to the flaps 44 except having no centralnotch, and extending from thegends of the panels 40 are the flaps 60which are similar to the aforementioned flaps 44 and 58, except thatflaps 60 along their outer edge are preferably straight as at 62,because these edges will belocated in themiddle of the top rail and donot have to be cut away for clear .ance.

Referring now to FIGURES 3, 4, 6 and 7, it will be seen that to make upa carton, the blank 32 is assembled with the end' panels by forming thecarton around the,

end panels and by forming the flaps 44, 58 and 60 around the wood rails,and inserting the outermost portions of 4 the forming of the flapsthereof around the top rails of the end panels. a V

The top panel means of the carton could, of course, be a single panel ifso desired. Further, the possibility presents itself of forming therails on the end panels of rolled up pieces of corrugated paper whichcould be integral with the end panels. It will be'undcrstood that, whererequired, the use of nails and staples in the carton to make the closingthereof more secure is not prevented and, likewise, sealing staples canbe applied to close the joint in the top panel as desired or necessary.

It is also contemplated Within the provision of the present invention toreinforce the carton additionally with wood strips which might bedesirable where thevcartons are to be stacked, This could be done byapplying the wood strips 70 extending across the parts 72 of the toppanel as indicated in FIGURE 8, These wood strips could be grooved,stapled or notched to the top parts of the panel if desired.

i It is also contemplated that reinforcing strips 74 of this. naturecould be applied to the undersides of the part 76, of, the. top panel asindicated .in FIGURE 9, and in which case, the top rails of the endmembers and the corrugated paper panels secured thereto would be notchedout at.78 for receiving the ends} of the strips 74. FIG

these flaps between the wood rails and the corrugated P paper members'that are attached to the inside faces of the rails. This is perhapsbrought out in FIGURE 7 wherein a typical connection of the naturereferred to is illustrated. consideredto be the top rail 14, the flap 60is formed In FIGURE 7, wherein the rail can be] about the rail and theend part of the flap outwardly from the outermost score'mark therein andindicated at 64 is being inserted between the corrugated paper member 20and the rail -14 to which thi member is secured by nailsor staples. Thecorrugated paper is relatively stilf so that once the portion 64 of theflap is pushed into the space between member 20 and rail 14, it issecurely held therein and can only be remo-vedby the use p of a'toolwhich can be inserted between theformed over flap and the rail to prythe flap out, or else the carton must be cutto get it open. Inconnection with the flaps formed around thecut rails, it will beappreciated that the notch 50 in the flaps 44 associated with panel 36are provided for preventing interference between these flaps and thenails holdingthe members 20 to the bottom rails of the .end panels inthe middle thereof. The cut off corners of the flaps 62 are provided forthis same purpose with respect torthe nails in the middle of the toprails. The carton completely set up as illustrated in FIG- URE 1 has allof the panels of the carton blank securely connected with the woodreinforced end panels of the carton and all of the wood is completelyenclosed so that the cartons can be manually handled quite comfortablywithout any danger of picking up splinters; Be cause of the tightconnection between the main carton blank and the cut reinforced endpanels, the carton is capable of withstanding considerable abuse withoutcom: ing apart and, furthermore, the full st-r'engthof the materialsmaking up the carton can be developed.

Inasmuch as no nails or other fastening means are required, the cartonis extremely inexpensiveto manufacture and. use. The end panels arefabricated and are only brought together with the main carton blank atthe point of use .of the carton. The carton can thus be shipped flat,which is conserving of space and shipping costs. No nailing machines orother devices are required at the point of use and the carton can becompletely set 'URE 9 also indicates certain other. features that couldbe included in the carton if desired, these'features includingventilating holes 80 whichcould be formed in any one of the number ofcarton walls and located where desired. Walls. of thisnature might berequired when the carton is used for shipping fruits orvegetables or thelike and could. be easily formed in the corrugated paper members at thetime of cutting thereof.

FIGURE 9 shows that the bottom panel of the corrugated paper cartonblank, instead of having long flaps thereon for wrapping around thebottom rails of the end panels,,could have shorter flaps 82 thereonlying along the outside'face of the bottom rails of the end panels 'andconnected thereto as: by nails or staples 84. This arrangement-will"permit the'end panels to be joined to such that it lends itself well topacking of household goods and the like for shipping. The cartons arestrong and easy to handle andremain securely closed. In connection withwork of this nature, however,.it,is desirable for the cartons to beeasily openable without destroying the carton because they can bere-used.

Itis also the case that many times when fruits or vegetables or the likeare shipped, the receiver might Wish to openthe carton Without damage.to it. The opening of the carton can be accomplished by pulling theflaps out that have been tucked in under the wood rails.

One way of doing this is to have a thin metal blade with a short book onthe end which can be slipped under the wood, rails so that the hookengages the innermost end of the flap, whereupon the flap can beeasilypulled out by the tool. In order to avoid the necessity of using a toolhowever, the present invention also contemplates i modifications such asshown in FIGURES 10, 11 and 12. V In FIGURES 10 and 11, what is dsclosedis pull tabs which are aflixed to the flaps at the ends of the two 1parts of the top panel as indicated at 92 in FIGURE 11.

These tabs are cemented or otherwise aflixed to the, end

portions of the flaps and may be adhesively connected to the end members20 or taped thereto if so desired. These tabs provide an easy means forpulling the flaps out when desired. I

I Another .way in which the carton could be formed so.

that it could be opened readily is illustrated in FIGURE 12 wherein theportions of the flap elements that extend over the bottoms of the topwood rails of the end members are scored as indicated at 04 in such amanner that a short tab 96 can be torn out and form a pull tab. The tabsQ6 as well as the tabs 90 provide means for pulling straight down on theterminal portions of the flaps and this will easily disengage the zlapsfrom the wood rails and permit the carton to be opened without damagethereto, while at the same time, the provision of the flaps in no waydecreases the ability of the carton to remain tightly closed duringhandling and shipping. All tucked in flaps could have such tabs ifdesired.

FIGURE 13 shows a somewhat modified arrangement in which a carton 80according to the present invention has two top panels 82 and 84 each ofan extent to extend completely across the top of the carton. With thisarrangement the uppermost flap could be provided with marginal portionsto form about the top rails '66 of the end members but it is alsopossible to form the panels as illustrated with a flap 83 on the outerportion of each side edge of the top flaps and in which case each of thetop flaps would be securely affixed to top rail 06.

It will be understood that additional nails or staples or adhesivescould be employed wherever desired if the carton were to be subjected torough handling for prolonged periods at a time. Similarly, the woodenframe for the end members could be glued at the corners if desired andthis would prevent the nails from becoming loose on account of thecarton being abused.

FIGURE 14 illustrates a modified arrangement wherein wood frame 100 foran end member of the carton has the corrugated paper panel 102 securedthereto by forming the panel with edge portions 104 which can be formedover one or more of the faces of the wood frame 100 and secured theretoby nails or staples or adhesive. When secured to the wooden frame byadhesive, the wood frame itself could be assembled with the cornersadhesively joined and then it could be pressed together with panel 102into a confining frame 1% which would hold the frame and panel togetheruntil the adhesive set up. This would make an extremely strong end paneland would not in anyway interfere with the connecting of the main panelsof the carton blank to the rails of the end members as has beendescribed above.

To summarize, the present invention provides a carton adapted for beingmanufactured in a variety of sizes and proportions and in connectionwith which all machinery such as cutting machinery, nailing and staplingmachinery,

and gluing and stitching devices would be eliminated at the point of useof the carton, and instead, the setting up and closing and lockingclosed of the carton would be a completely manual operation, which canbe done quickly and inexpensively.

It will be understood that this invention is susceptible to modificationin order to adapt it to different usages and conditions; andaccordingly, it is desired to comprehend such modifications within thisinvention as may fall within. the scope of the appended claims.

I claim:

1. In a carton blank; comprising bottom, side and top panel meanshingedly interconnected and forming a substantially rectangular blank,end members for the carton comprising end panels and rigid railsextending along the edges of said panels on the outside each end memberhaving a width corresponding to the width of the bottom panel means anda height corresponding to the height of said side panel means, each saidpanel means of the blank having liap means hingedly connected theretoand scored along lines parallel to the ends of the panel means andspaced apart to divide the flap means into hingedly interconnectedportions, each said flap means being arranged for being formed about theadjacent wood rail of the adjacent end member and the terminal portionof each said flap means remote from the connection of the flap means tothe panel being receivable in the region between the said end panel andthe rail about which the flap means is formed, the said portion of eachflap means adjacent the connection of the flap means with its respectivepanel means being beveled inwardly toward the center of the respectiveflap means so said flap means will be in edge to edge engagement whenformed about said rails, said flap means having the ends of saidterminal portions beveled to facilitate insertion thereof between therails and the pertaining end panel, means connecting said end panels tosaid rails comprising connector elements in the corners of the panelswhich also extend through the rails so as to interconnect the rails atthe corners of the panels, and additional connectors intermediate theends of the top and bottom rails, and the flap means pertaining to thetop and bottom panel means being notched intermediate their ends toprevent interference with said last mentioned connectors. I

2. A carton according to claim 1 in which at least the terminal portionsof said flap means pertaining to said top pull means have pull tabsconnected thereto and proiecting outwardly from between the respectiverail and end panel for disengaging the said flap means from the railsabout which they are formed.

3. A carton according to claim 1 in which said top panel means havereinforcing strips extending thereacross from end to end and overlyingsaid end members when said top panel means are folded down at the endmembers.

4. A carton according to claim 1 in which each said top panel meansextends substantially completely across the top of the carton therebyproviding for a double-ply carton top, and the said flap means on eachof said top panels extending along the length of about one half the toprails of the end members from the outer edges of the respective toppanels.

5. A carton according to claim 1 in which said end panels have edgeportions formed at least part way around said rigid rails and securedthereto.

6. A carton according to claim 2 in which said pull tab means areportions of the respective flap means formed by cutting the flap meanspart Way around the tab means and turning the tab means out from theflap means.

References Cited by the Examiner UNIT ED STATES PATENTS 1,202,042 10/16Fairchild et al.

1,352,062 9/20 Hentschel 215-51 1,558,155 10/25 Flansburg 229-411,963,272 6/34 Kammert 229-23 2,071,962 2/37 Babcock 22923 X 2,262,26711/41 Boeye 229-23 2,538,204 1/51 Zemon 22 -23 X 2,988,209 6/61Parrilla.

3,069,043 12/62 Bishop 229-3.5 X

FOREIGN PATENTS 444,921 3/36 Great Britain.

FRANKLIN T. GARRETT, Primary Examiner.

1. IN A CARTON BLANK; COMPRISING BOTTOM, SIDE AND TOP PANEL MEANSHINGEDLY INTERCONNECTED AND FORMING A SUBSTANTIALLY RECTANGULAR BLANK,END MEMBERS FOR THE CARTON COMPRISING END PANELS AND RIGID RAILSEXTENDING ALONG THE EDGES OF SAID PANELS ON THE OUTSIDE EACH END MEMBERHAVING A WIDTH CORRESPONDING TO THE WIDTH OF THE BOTTOM PANEL MEANS ANDA HEIGHT CORRESPONDING TO THE HEIGHT OF SAID SIDE PANEL MEANS, EACH SAIDPANEL MEANS OF THE BLANK HAVING FLAP MEANS HINGEDLY CONNECTED THERETOAND SCORED ALONG LINES PARALLEL TO THE END OF THE PANEL MEANS AND SPACEDAPART TO DIVIDE THE FLAP MEANS INTO HINGEDLY INTERCONNECTED PORTIONS,EACH SAID FLAP MEANS BEING ARRANGED FOR BEING FORMED ABOUT THE ADJACENTWOOD RAIL OF THE ADJACENT END MEMBER AND THE TERMINAL PORTION OF EACHSAID FLAP MEANS REMOTE FROM THE CONNECTION OF THE FLAP MEANS TO THEPANEL BEING RECEIVABLE IN THE REGION BETWEEN THE SAID END PANEL AND THERAIL ABOUT WHICH THE FLAP MEANS IS FORMED, THE SAID PORTION OF EACH FLAPMEANS ADJACENT THE CONNECTION OF THE FLAP MEANS WITH ITS RESPECTIVEPANEL MEANS BEING BEVELED INWARDLY TOWARD THE CENTER OF THE RESPECTIVEFLAP MEANS SO SAID FLAP MEANS WILL BE IN EDGE TO EDGE ENGAGEMENT WHENFORMED ABOUT SAID RAILS, SAID FLAP MEANS HAVING THE ENDS OF SAIDTERMINAL PORTIONS BEVELED TO FACILITATE INSERTION THEREOF BETWEEN THERAILS AND THE PERTAINING END PANEL, MEANS CONNECTING SAID END PANELS TOSAID RAILS COMPRISING CONNECTOR ELEMENTS IN THE CORNERS OF THE PANELSWHICH ALSO EXTEND THROUGH THE RAILS SO AS TO INTERCONNECT THE RIALS ATTHE CORNERS OF THE PANELS, AND ADDITIONAL CONNECTORS INTERMEDIATE THEENDS OF THE TOP AND BOTTOM RAILS, AND THE FLAP MEANS PERTAINING TO THETOP AND BOTTOM PANEL MEANS BEING NOTCHED INTERMEDIATE THEIR ENDS TOPREVENT INTERFERENCE WITH SAID LAST MENTIONED CONNECTORS.